The document describes a project at Yanbu Industrial College to improve operations on an EMCO Mill 155 CNC machine. The objectives were to fully operate the machine and add capabilities to solve problems with zero point setting, tool offsets, and job clamping. A new vice was designed to increase the size of parts that could be clamped. The zero point and tool length measurement process was also improved to reduce setup time and enhance machining operations. An example program is provided to machine a coupling using the new vice and settings.
3. 1- Project objectives.
2- Introduction.
3- Mission of the project.
4-The work done.
a- Job clamping.
b- Zero point setting.
c- Tool length measurement.
5-T he example.
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4. THEOBJECTIVE
To operate EMCO Mill 155 machine
fully and to add more facilities to it
to enhance and maximize it’s
operations.
Also, to solve some problems which
affect the machine setting time.
These problems can be summarized
in:
• Zero setting position.
•Tools offset.
• Job clamping
Operate fully
Adding facilities
Solve some problems
Example
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6. 6
Numerical Control (NC) : means
control by numbers.
Computer Numerical Control
(CNC) is any computer-controlled
device that can be programmed to
perform a task (machining
operations).
8. Concept EMCOMill155Specification…
Travel (X/Y/Z) : 300/200/300 mm
Milling table (L *W) : 520 * 180 mm
Spindle speed range : 150-5000 or
1000 R/min
Machine weight : 700 kg
Power supply :400 v , 50/60 Hz
Machine dimensions (L*D*H) :
1502*1284*1925 mm
3 axis CNC machining center.
Integrated PC and 12" flat display.
Hardened guide ways.
Central lubrication.
Machine lamp.
Fully enclosed inclusive chip tray.
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9. TheMission
To study the EMCO mill 155
machine clamping process
improvement; to increase the
capability of job clamping.
Also to reduce setting time
and enhance machining
operations.
1-Job Clamping
3-Tool length measurement
2-Zero setting point
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11. JobClamping
The machine pneumatic vice
can carry only rectangular jobs
of exact dimensions of 140
mm X 100 mm and round jobs
of only 30 mm & 40 mm.
Hence one of the objectives is
to increase the machine
capacity to carry different job
sizes by designing a new vice.
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17. ZeroPointsetting
The job zero point is set at the
pneumatic vice left back carrier. If
any different job setting is used,
then the machine will lose the X and
Y position. So in the new vice a new
setting is needed. (The zero point
must be kept because the system
needs it for FMS work)
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18. 18
This position is for new vice
• For X and Y position
• Transfer X to (+19.9 mm)
• Transfer Y to (+ 3.2 mm + 100 mm)
19. 19
For Z axis
• Z (varies) = (standard number 184.540 mm ) – (vice
material thickness + height of the work piece)
• Vice material thickness (9.6 mm)
height of the
work piece
vice material
thickness
21. ToollengthMeasuring(tool-offset)
Tools used to be set by try
and error. A system is
designed to measure the
exact tool length.Then
the tool length is register
on the machine tools
offset.
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23. 23
To set Z axis:
1- Measure tool length and register it in the machine control.
2-Touch on the vice face (base 184.54 mm) and recording the
number.
3- Subtract 9.6 mm (vice material thickness) from the
recorded number.
(If the job height is 50mm thenThe final value for X is 124.818
mm.)
Tool length measuring procedure
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offset of Z = touch over the vice (constant =184.54
mm ) – touch over the job
offset of Z = 184.54 – 124.818 = 59.72 mm
Then register the offset on the commandTRANS
(eg. TRANSE Z59.72 ).
Example:
25. Example
"Old ham's Coupling" is machined
by using the mentioned settings:
The coupling consists of three pieces
with a diameter of 70 mm and
height of 40 mm and to be made
from polystyrene(Teflon) material.
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